Automatic container loading system and method for lifting machinery

Abstract

This invention proposes an automatic container loading system and method for lifting machinery. The system includes a TOF stereo camera mounted on the spreader, with its shooting direction tilted downwards, used to acquire the height difference Z between the spreader and the container top, the horizontal distance X between the spreader and the container top along the long side of the container, and the horizontal distance Y between the spreader and the container top along the short side of the container. The spreader, mounted on the gantry, can move up and down and sideways along the gantry. Based on the point cloud data formed by the above three degrees of freedom parameters, it detects the container's shape and the relative position of the container's lifting holes, and outputs the container's shape signal and the relative position signal of the container's lifting holes. A loading sensor, mounted on the spreader, detects whether the spreader has loaded the container. This invention can achieve automatic alignment between the lock on the spreader and the container's lifting holes.

Description

Technical Field

[0001] This invention belongs to the field of container loading technology, and particularly relates to an automatic container loading system and method for lifting machinery. Background Technology

[0002] During container stacker operations, the operator must control the gantry's pitch and roll movements, as well as the spreader's lateral and vertical movements, via control levers in the operator's cab to perform tasks such as container alignment and stacking. Currently, most container stackers employ a feedforward open-loop control system for this operation. Figure 1 This diagram illustrates the control architecture of a container stacker's container handling system in the prior art. Figure 1 As can be seen, the operator sends a control signal to the main controller 3 by manipulating the control handle. The main controller 3 controls the movement of the gantry action control valve and the spreader action control valve based on the received control signal, thereby controlling the pitch of the gantry 1 and the lateral movement and lifting of the spreader 2 of the container stacker to carry out container handling operations.

[0003] Therefore, the traditional manual crane loading and unloading method for containers has the following drawbacks: the driver needs to visually observe the position of the container lifting hole and the position of the spreader lock head, and manually operate to accurately insert the spreader lock head into the container lifting hole. The operation process is complicated, requires high operator skills, and is prone to hand fatigue. It is a key factor restricting the efficiency of container loading and unloading and cannot meet the needs of container transportation development. Summary of the Invention

[0004] The purpose of this invention is to provide an automatic container loading system and method for lifting machinery, which can automatically align the lock on the spreader with the container lifting hole. To achieve the above objective, this invention adopts the following technical solution:

[0005] An automated container loading system for lifting machinery includes: a gantry 1; a spreader 2, mounted on the gantry 1 and capable of vertical lifting and horizontal movement along the gantry; a main controller 3, controlling the movement of the gantry 1 and the spreader 2; and further includes:

[0006] The space status sensor of the lifting device detects the space status of the lifting device 2 and outputs the space status signal of the lifting device to the main controller 3;

[0007] The space status sensor of the lifting device detects the space status of the lifting device 2 and outputs the space status signal of the lifting device to the main controller 3;

[0008] A TOF stereo camera is mounted on the spreader 2, with the shooting direction downwards, to obtain the height difference Z between the spreader and the top of the container, the distance X between the spreader and the long side end of the container, and the distance Y between the spreader and the short side end of the container;

[0009] An image information processor is located on the side of the spreader 2. Based on the point cloud data formed by the above three degrees of freedom parameters, it detects the container shape and the relative position of the container lifting hole, and outputs the container shape signal and the relative position signal of the container lifting hole.

[0010] A container-attaching sensor is installed on the spreader 2 to detect whether the spreader is attaching to the container; an image information processor receives the container shape signal and the container position signal, and communicates with the host controller 3 to receive the spreader spatial status signal from the host controller 3, calculates the relative position between the lock on the spreader 2 and the container lifting hole based on the above signals, and calculates the optimal movement path trajectory of the spreader 2.

[0011] The host controller 3 obtains the calculated optimal motion path trajectory through a communication connection with the image information processor, and controls the movement of the lifting device 2 according to the optimal motion path trajectory.

[0012] Preferably, the TOF stereo camera is mounted on the column 21 of the hoist 2.

[0013] Preferably, the spatial state sensor of the lifting device includes: a length sensor, one end of which is fixed and the other end is installed on the lifting device 2 to detect the height of the lifting device 2; and a displacement sensor, which is installed on the lateral displacement cylinder of the lifting device 2 and moves along the X direction with the lateral displacement cylinder to detect the lateral displacement of the lifting device 2.

[0014] An automatic container loading method for lifting machinery includes: S1, switching to automatic container loading mode, and the image information processor determining whether a height difference Z is received; if so, step S2 is executed.

[0015] S2. The image information processor determines whether distance X and distance Y are both within their respective threshold ranges; if so, step S3 is executed; otherwise, an adjustment command is sent to the host controller 3, and the host controller 3 controls the movement of the gantry 1 and the lifting device 2.

[0016] S3. The image information processor sends a descent command to the host controller 3, and the host controller controls the movement of the gantry 1 and the lifting device 2.

[0017] S4: The image information processor determines whether the relative position between the lock on the spreader 2 and the container lifting hole is within the set threshold range. If so, the image information processor sends a descent command to the host controller 3, and the host controller 3 controls the spreader 2 to continue descending along the optimal motion path trajectory.

[0018] S5: When the box sensor sends a signal to the image information processor, the lock head and the lifting hole are connected.

[0019] Preferably, before step S1, the method further includes: determining whether the automatic container loading system used for lifting machinery meets the detection conditions; if so, then step S1 is executed; wherein the detection conditions are:

[0020] The distance Y between the spreader and the short side end of the container is 0; the distance X between the spreader and the long side end of the container is 500mm≤X<1000mm; the height difference between the spreader and the top of the container is 500mm≤Z<1000mm.

[0021] Compared with the prior art, the advantages of the present invention are:

[0022] (1) It can overcome the problems of high driver skill requirements, complex hole alignment process, and easy driver fatigue caused by manual gearbox operation.

[0023] (2) It can shorten the time for identifying, locating and locking the container hoisting hole, shorten the container loading and unloading cycle, and improve the container stacking efficiency. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the structure of a container alignment system in the prior art;

[0025] Figure 2 This is a schematic diagram of the control architecture of the automatic container loading system for lifting machinery according to the present invention;

[0026] Figure 3 This is a flowchart of the automatic container loading method for lifting machinery according to the present invention;

[0027] Figure 4 This is a schematic diagram of the automatic container loading system for lifting machinery according to the present invention.

[0028] Among them, 1-gantry, 2-suspension device, 21-column, 3-main controller. Detailed Implementation

[0029] The present invention will now be described in more detail with reference to the accompanying drawings, which illustrate preferred embodiments of the invention. It should be understood that those skilled in the art can modify the invention described herein while still achieving its advantageous effects. Therefore, the following description should be understood as being of general knowledge to those skilled in the art and is not intended to limit the invention.

[0030] like Figures 2-4 As shown, an automatic container stacking system for lifting machinery is used for automatic stacking. During the automatic stacking control process, only the degrees of freedom in the left-right lateral movement (X) and lifting (Z) directions are adjusted. Specifically, it includes: a gantry 1, a spreader 2, a main controller 3, an image information processor, a spreader spatial status sensor, a TOF stereo camera, and a container stacking sensor. As is known from existing technology, the lateral movement control valve and the lifting control valve are used to control the spreader 2, respectively.

[0031] In this embodiment, the gantry 1 can be tilted, but in this embodiment, its angle is set to zero, that is, it only remains in a vertical state.

[0032] The lifting device 2 is installed on the gantry 1 and can be raised, lowered and moved left and right along the gantry 1.

[0033] The main controller 3 controls the movement of the gantry 1 and the lifting device 2.

[0034] A spatial status sensor for the lifting device detects the spatial status of the lifting device 2 and outputs a spatial status signal to the main controller 3. The spatial status sensor includes: a length sensor, specifically a CET12.10000.2.6.1.X length sensor, with one end fixed and the other end mounted on the lifting device 2 to detect the height of the lifting device 2; and a displacement sensor, mounted on the lateral displacement cylinder of the lifting device 2 and moving along the X-axis with the lateral displacement cylinder to detect the lateral displacement of the lifting device 2.

[0035] A pair of TOF stereo cameras are symmetrically mounted on the column 21 of the spreader 2. The camera is tilted downwards to acquire the height difference Z between the spreader and the top of the container, the distance X between the spreader and the long side end of the container, and the distance Y between the spreader and the short side end of the container. The data collected by the TOF stereo cameras forms point cloud data, which can be used to display the three-dimensional shape near the container's lifting hole.

[0036] An image information processor, located on the side of the spreader 2, detects the container's shape and the relative position of the container's lifting holes based on the point cloud data formed by the aforementioned three degrees of freedom parameters, and outputs the container's shape signal and the relative position signal of the container's lifting holes. Specifically, based on the pixel position information stored in the point cloud dataset, it calculates the feature information such as the lifting holes and sides in the container image, matches it with the container dimensions, and gradually constructs and improves the container outline model through comparison and optimization to achieve container shape detection.

[0037] The image information processor receives container shape signals and container position signals, and communicates with the host controller 3. It receives gantry space status signals and spreader space status signals from the host controller 3. Based on the above signals, it calculates the relative position between the lock head on the spreader 2 and the container lifting hole, and calculates the optimal motion path trajectory of the spreader 2.

[0038] A container-landing sensor, installed on the lifting sling, detects whether the sling has landed on the container. The lifting sling control module in the image information processor monitors the container-landing signal in real time. Once successful landing is confirmed, the locking mechanism performs a locking action and returns a locking success signal.

[0039] The host controller 3 obtains the calculated optimal motion path trajectory through communication with the processing unit, and controls the movement of the gantry 1 and the sling 2 according to the optimal motion path trajectory.

[0040] like Figure 3 As shown, the automatic container landing method for lifting machinery includes: determining whether the automatic container landing system for lifting machinery meets the detection conditions; if so, proceeding to step S1; wherein, the detection conditions are:

[0041] The distance Y between the spreader and the short side end of the container is 0; the distance X between the spreader and the long side end of the container is 500mm≤X<1000mm; the height difference between the spreader and the top of the container is 500mm≤Z<1000mm.

[0042] S1. Switch to automatic box alignment mode. The image information processor determines whether the height difference Z is received. If so, proceed to step S2.

[0043] S2. The processing unit determines whether distance X and distance Y are both within their respective threshold ranges; if so, it executes step S3; otherwise, it sends an adjustment command to the host controller 3, and the host controller 3 controls the movement of the gantry 1 and the lifting device 2.

[0044] S3. The image information processor sends a descent command to the host controller 3, and the host controller controls the movement of the gantry 1 and the lifting device 2.

[0045] S4: The image information processor determines whether the relative position between the lock on the spreader 2 and the container lifting hole is within the set threshold range. If so, the image information processor sends a descent command to the host controller 3, and the host controller 3 controls the spreader 2 to continue descending along the optimal motion path trajectory.

[0046] S5: When the box sensor sends a signal to the image information processor, the lock head and the lifting hole are connected.

[0047] The above are merely preferred embodiments of the present invention and do not constitute any limitation on the present invention. Any equivalent substitutions or modifications made by those skilled in the art to the technical solutions and content disclosed in the present invention without departing from the scope of the present invention shall be deemed to have remained within the protection scope of the present invention.

Claims

1. An automatic container loading system for lifting machinery, comprising: A gantry (1); a lifting device (2) is installed on the gantry (1) and can move up and down and sideways along the gantry; The main controller (3) controls the movement of the gantry (1) and the lifting device (2); characterized in that it further includes: The space status sensor of the lifting device detects the space status of the lifting device (2) and outputs the space status signal of the lifting device to the host controller (3); the space status sensor of the lifting device includes: a length sensor, one end of which is fixed and the other end is installed on the lifting device (2) to detect the height of the lifting device (2); a displacement sensor, which is installed on the side displacement cylinder of the lifting device (2) and moves along the X direction with the side displacement cylinder to detect the lateral displacement of the lifting device (2); A TOF stereo camera is set on the spreader (2) with the shooting direction downward, and is used to obtain the height difference Z between the spreader and the top of the container, the distance X between the spreader and the long side end of the container, and the distance Y between the spreader and the short side end of the container. An image information processor is set on the side of the spreader (2). Based on the point cloud data formed by the above three degrees of freedom parameters, it detects the relative position of the container shape and the container lifting hole, and outputs the container shape signal and the relative position signal of the container lifting hole. A container contact sensor is installed on the spreader (2) to detect whether the spreader is contacting the container; an image information processor receives the container shape signal and the container position signal, and communicates with the host computer. The controller (3) is connected to the communication and receives the spatial status signal of the spreader from the host controller (3). Based on the above signal, it calculates the relative position between the lock head on the spreader (2) and the container lifting hole, and calculates the optimal motion path trajectory of the spreader (2). The host controller (3) obtains the calculated optimal motion path trajectory through a communication connection with the image information processor, and controls the action of the lifting device (2) according to the optimal motion path trajectory.

2. The automatic container loading system for lifting machinery according to claim 1, characterized in that, The TOF stereo camera is mounted on the column of the hoist (2).

3. A method for an automatic container loading system for lifting machinery according to any one of claims 1 to 2, characterized in that, include: S1. Switch to automatic box alignment mode. The image information processor determines whether the height difference Z is received. If so, proceed to step S2. S2. The image information processor determines whether distance X and distance Y are both within their respective threshold ranges; if so, step S3 is executed; otherwise, an adjustment command is sent to the host controller (3), and the host controller (3) controls the movement of the gantry (1) and the lifting device (2). S3. The image information processor sends a descent command to the host controller (3), and the host controller controls the movement of the gantry (1) and the lifting device (2); S4: The image information processor determines whether the relative position between the lock on the spreader (2) and the container lifting hole is within the set threshold range. If so, the image information processor sends a descent command to the host controller (3), and the host controller (3) controls the spreader (2) to continue descending along the optimal motion path trajectory. S5: When the box sensor sends a signal to the image information processor, the lock head and the lifting hole are connected.

4. The method for an automatic container loading system for lifting machinery according to claim 3, characterized in that, Before step S1, the method further includes: determining whether the automatic container loading system used for lifting machinery meets the detection conditions; if so, then proceeding to step S1; wherein, the detection conditions are: The distance Y between the spreader and the short side end of the container is 0; the distance X between the spreader and the long side end of the container is 500mm≤X<1000mm; the height difference between the spreader and the top of the container is 500mm≤Z<1000mm.

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